Morphing segmented wind turbine and related method

ABSTRACT

A downwind morphing rotor that exhibits bending loads that will be reduced by aligning the rotor blades with the composite forces. This reduces the net loads on the blades which therefore allow for a reduced blade mass for a given maximum stress. Also provided is a pre-aligned configuration rotor whereby the rotor geometry and orientation does not change with wind speed, and instead is fixed at a constant downwind deflection consistent with alignment at or near the rated wind speed conditions. Also provided is a twist morphing rotor where the airfoil-shapes around the spars twist relative to the wind due to aerodynamic forces so as to unload the rotors when there is a gust. This can help reduce unsteady stresses on the blade and therefore may allow for reduced blade mass and cost. The twist morphing rotor may be combined with either downwind morphing rotor or pre-alignment rotor.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from U.S. ProvisionalApplication Ser. No. 61/499,507, filed Jun. 21, 2011, entitled “MorphingSegmented Wind Turbine and Related Method” and U.S. ProvisionalApplication Ser. No. 61/661,513, filed Jun. 19, 2012, entitled “MorphingSegmented Wind Turbine and Related Method;” the disclosures of which arehereby incorporated by reference herein in their entirety.

BACKGROUND OF THE INVENTION

Wind energy is a key to the nation's 2030 goals of increased energyindependence and reduced environmental impact stemming from powergeneration (Lindenberg et al. 2008). It is projected to account for asmuch as 20% of U.S. power by 2030. This sustainable source will improvethe nation's energy independence and allow a low environmental impact ascompared to traditional fossil fuels in many ways. Firstly, it canreduce energy related emissions since the 20% wind penetration by 2030is estimated by the U.S. Department of Energy (DOE) to avoid 2,100million metric tons of carbon into the atmosphere. Secondly, estimatesby Jacobsen (2009) indicate that 300 GW of wind power primarily used forcharging electric-battery vehicles would eliminate 15,000emissions-related deaths per year by 2020. This would also eliminate 15million barrels per day of imported oil in the United States, reducingthe amount of imported energy and increasing our energy independence andsecurity.

Maintaining or lowering cost of energy while simultaneously ramping uptotal installed penetration may benefit from revolutionary advances inturbine concepts at extreme-scales (diameters of 120 meters and beyond)with improved efficiency. This increase in scale and efficiency has beenevident in recent wind turbine design. The average wind turbine ratedpower has increased twenty-fold since 1985, with present systemsaveraging 2 MW. Economies of scale and higher winds aloft are drivingsystems to power levels of 5 MW and beyond with rotor diameters (D)nearing 120 m and greater. While larger systems are needed in thefuture, blade weight (currently proportional to D^(2.35)) has become aconstraining design factor due to high gravity loads (Ashwill, 2009).This scaling is important since system costs generally scale linearlywith system weight and the rotor itself accounts for about 23% of theinitial total system cost (Fingersh, 2006). In addition, noise (andvisual) production is likely to be very significant for extreme-scalesystems indicating that such systems are best suited for off-shoresiting. Such siting may also reduce many existing environmental impactsbut leads to complications in terms of installation and maintenance.These problems are compounded by upwind turbine configurations sincesuch designs necessitate stiff blades to avoid rotor-blade towerstrikes. Moreover, overly rigid rotor/tower systems lead to problematichigh frequency fatigue loads.

SUMMARY OF EXEMPLARY EMBODIMENTS OF THE INVENTION

A morphing segmented concept is submitted herein as an embodiment of thepresent invention for future extreme-scale wind turbine systems. Both“twist morphing” and “downwind morphing” can be employed.

The twist morphing pertaining to an embodiment of the present inventionmay be accomplished by using segmented blades connected by screw socketsand a tension cable system (as well as other available couplingmechanisms and tension control systems). At low wind and rotor speeds,the segmented blades may be, for example, fully tensioned and set athigh pitch to ensure start-up and maximum power at low speeds. At highrotor rpm, the cable tension can be designed such that centrifugalforces drive the blade segments outward so as to unwind/feather therotor and prevent over-speed. This effectively acts like a passive pitchcontrol for rotor speeds. Perhaps more importantly, still referring tothe “twist morphing” rotor the airfoils of the blade segments can bedesigned with a center of pressure downstream of the socket axis. Thiswill cause an aerodynamic moment at high wind speeds which will serve tounwind the blade segments to prevent torque spikes and blade stall. Fora given rotor diameter and torque, such stall prevention can permitoperation at higher average lift coefficient with a reduced blade chordlength which can reduce blade and overall system weight. In addition,the segmented blade concept can alleviate manufacturing and shippingconstraints for extreme-scale systems. In the proposed concepts, thebending loads will be carried by the segmented rotor spar and not theblade skin. This may result in much larger downstream deflections of theblades at high wind speeds as compared to that of a conventional rigidsingle-piece turbine blade.

Pertaining to an embodiment of the “downwind morphing” rotor, thebending loads will be reduced by aligning the rotor blades with thecomposite forces. This reduces the net loads on the blades, whichtherefore allow a reduced blade mass for a given maximum stress. Thedownwind morphing varies the amount of downstream deflection as afunction of wind speed, where the rotor blades are generallyfully-aligned to non-azimuthal forces for wind speeds between rated andcut-out conditions, while only the outer segments of the blades aregenerally aligned between cut-in and rated wind speeds. This alignmentfor large (MW-scale) rated turbines results in much larger downstreamdeflections of the blades at high wind speeds as compared to that of aconventional rigid single-piece upwind turbine blade. Therefore, adownstream design would be needed for the downwind morphing to avoidpotential strike of the blades with the tower. This will require a moreaerodynamic tower to reduce wake interactions, but a downstream systemmay eliminate yaw-control and substantially relax blade rigidityconstraints, thus further reducing blade weight. An aspect of anembodiment of the present invention rotor provides an aligned conceptthat employs a geometry that orients the loads (i.e., net force) alongthe blade length of the blade so that the structural loads primarily actin the tension mode. The blade may have two or more blade segments orportions that may be joined at blade segment joints so as to be able tofold or close (partially or fully) downwind. In general, for speedssignificantly below rated conditions, the blades could be fixed on thevertical plane in order to maximize the swept area allowed with thelonger length blades. As the wind speed approaches rated conditions, theblades could be gradually released in semi-alignment to reduce stresses.For rated speeds and above, the blades could be fully-aligned, though adashpot-damper system may be needed to avoid problematic dynamics.Finally, at speeds significantly above cut-out conditions, the stoppedblades could be closed-up towards the horizontal to allow a stowconfiguration for hurricane level winds.

An alternative embodiment to downwind morphing is a “pre-aligned”configuration, where the rotor geometry and orientation does not changewith wind speed, and instead is fixed at a constant downwind deflectionconsistent with alignment at or near the rated wind speed conditions.

Another embodiment is morphing based on twist, where the airfoil-shapesaround the spars twist relative to the wind due to aerodynamic forces soas to unload the rotors when there is a gust. This can help reduceunsteady stresses on the blade and therefore may allow for reduced blademass and cost. It should be appreciated that twist morphing may becombined with either downwind morphing or it may be combined withpre-alignment.

An aspect of an embodiment of the present invention provides, but notlimited thereto, a rotor blade for a wind turbine. The blade maycomprise: a plurality of blade segments for use as part of a rotor; theplurality of blade segments may comprise an internal passage extendinglongitudinally from a first end to a second end of each of the bladesegments; a plurality of spar members extending longitudinally throughthe internal passages of each of the blade segments such that theplurality of the spar members are aligned and in communicationend-to-end through the internal passages and the plurality of bladesegments are aligned and in communication with the aligned spar membersand define a complete rotor blade from a root that connects to a rotorhub to a blade tip of the rotor blade; a tension member extendinglongitudinally through the aligned spar members; and the aligned sparmembers are configured to at least partially unwind due to centrifugalforces exerted on the blade segments and aligned spar members, theunwound spar members causing the blade segments to twist and providetwist morphing relative to the spar members.

An aspect of an embodiment of the present invention provides, but notlimited thereto, a method of manufacturing a rotor blade for a windturbine. The method may comprise: providing a plurality of bladesegments for use as part of a rotor; the plurality of blade segments maycomprise an internal passage extending longitudinally from a first endto a second end of each of the blade segments; providing a plurality ofspar members extending longitudinally through the internal passages ofeach of the blade segments such that the plurality of the spar membersare aligned and in communication end-to-end through the internalpassages and the plurality of blade segments are aligned and incommunication the aligned spar members and define a complete rotor bladefrom a root that connects to a rotor hub to a blade tip of the rotorblade; providing a tension member extending longitudinally through thealigned spar members; and the aligned spar members are configured to atleast partially unwind due to centrifugal forces exerted on the bladesegments and aligned spar members, the unwound spar members causing theblade segments to twist and provide twist morphing relative to the sparmember.

An aspect of an embodiment of the present invention provides, but notlimited thereto, a rotor blade kit for forming rotor blade on a windturbine. The kit may comprise: a plurality of blade segments for use aspart of a rotor; the plurality of blade segments may comprise aninternal passage extending longitudinally from a first end to a secondend of each of the blade segments; a plurality of spar members forextending longitudinally through the internal passages of each of theblade segments such that the plurality of the spar members are alignedand in communication end-to-end through the internal passages and theplurality of blade segments are aligned and in communication the alignedspar members and define a complete rotor blade from a root that connectsto a rotor hub to a blade tip of the rotor blade; a tension member forextending longitudinally through the aligned spar members; and thealigned spar members are configured to at least partially unwind due tocentrifugal forces exerted on the blade segments and aligned sparmembers, the unwound spar members causing the blade segments to twistand provide twist morphing relative to the spar member.

An aspect of an embodiment of the present invention provides, but notlimited thereto, an individual blade segment for a wind turbine that isformed from a plurality of the individual blade segments, whereby theindividual blade segments may comprise an internal passage extendinglongitudinally from a first end to a second end of each of the bladesegments; wherein a plurality of spar members extend longitudinallythrough the internal passages of each of the blade segments such thatthe plurality of the spar members are aligned and in communicationend-to-end through the internal passages and the plurality of bladesegments are aligned and in communication the aligned spar members anddefine a complete rotor blade from a root that connects to a rotor hubto a blade tip of the rotor blade; a tension member extendslongitudinally through the aligned spar members; and wherein the alignedspar members are configured to at least partially unwind due tocentrifugal forces exerted on the blade segments and aligned sparmembers, the unwound spar members causing the blade segments to twistand provide twist morphing relative to the spar members.

An aspect of an embodiment of the present invention provides, but notlimited thereto, a rotor blade for a wind turbine. The blade maycomprise: a plurality of blade segments for use as part of a rotor; theplurality of blade segments may comprise an internal passage extendinglongitudinally from a first end to a second end of each of the bladesegments; a plurality of spar members extending longitudinally throughthe internal passages of each of the blade segments such that theplurality of the spar members are aligned and in communicationend-to-end through the internal passages and the plurality of bladesegments are aligned and in communication with the aligned spar membersand define a complete rotor blade from a root that connects to a rotorhub to a blade tip of the rotor blade; and the aligned spar members andblade segments are configured to pivot due to centrifugal forces exertedon the blade segments and aligned spar members, the pivoted spar membersand blade segments causing the blade segments to provide a curvaturedefining a deflection angle relative to the axis of rotation plane ofthe rotor blade.

An aspect of an embodiment of the present invention provides, but notlimited thereto, a method of manufacturing a rotor blade for a windturbine. The method may comprise: providing a plurality of bladesegments for use as part of a rotor; the plurality of blade segments maycomprise an internal passage extending longitudinally from a first endto a second end of each of the blade segments; providing a plurality ofspar members extending longitudinally through the internal passages ofeach of the blade segments such that the plurality of the spar membersare aligned and in communication end-to-end through the internalpassages and the plurality of blade segments are aligned and incommunication the aligned spar members and define a complete rotor bladefrom a root that connects to a rotor hub to a blade tip of the rotorblade; and the aligned spar members and blade segments are configured topivot due to centrifugal forces exerted on the blade segments andaligned spar members, the pivoted spar members and blade segmentscausing the blade segments to provide a curvature defining a deflectionangle relative to the axis of rotation plane of the rotor blade.

An aspect of an embodiment of the present invention provides, but notlimited thereto, a rotor blade kit for forming rotor blade on a windturbine. The kit may comprise: a plurality of blade segments for use aspart of a rotor; the plurality of blade segments may comprise aninternal passage extending longitudinally from a first end to a secondend of each of the blade segments; a plurality of spar members forextending longitudinally through the internal passages of each of theblade segments such that the plurality of the spar members are alignedand in communication end-to-end through the internal passages and theplurality of blade segments are aligned and in communication the alignedspar members and define a complete rotor blade from a root that connectsto a rotor hub to a blade tip of the rotor blade; and the aligned sparmembers and blade segments are configured to pivot due to centrifugalforces exerted on the blade segments and aligned spar members, thepivoted spar members and blade segments causing the blade segments toprovide a curvature defining a deflection angle relative to the axis ofrotation plane of the rotor blade.

An aspect of an embodiment of the present invention provides, but notlimited thereto, an individual blade segment for a wind turbine that isformed from a plurality of the individual blade segments, whereby theindividual blade segments comprise an internal passage extendinglongitudinally from a first end to a second end of each of the bladesegments; wherein a plurality of spar members extend longitudinallythrough the internal passages of each of the blade segments such thatthe plurality of the spar members are aligned and in communicationend-to-end through the internal passages and the plurality of bladesegments are aligned and in communication the aligned spar members anddefine a complete rotor blade from a root that connects to a rotor hubto a blade tip of the rotor blade; and wherein the aligned spar membersand blade segments are configured to pivot due to centrifugal forcesexerted on the blade segments and aligned spar members, the pivoted sparmembers and blade segments causing the blade segments to provide acurvature defining a deflection angle relative to the axis of rotationplane of the rotor blade.

These and other objects, along with advantages and features of variousaspects of embodiments of the invention disclosed herein, will be mademore apparent from the description, drawings and claims that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features and advantages of the presentinvention, as well as the invention itself, will be more fullyunderstood from the following description of preferred embodiments, whenread together with the accompanying drawings.

FIG. 1(A) provides a perspective view of a modern conventional turbine.

FIG. 1(B) provides a schematic view of the associated net forces summedat quarter elements on a respective conventional blade of FIG. 1(A).

FIG. 1(C) provides a perspective view of an aspect of an embodiment ofthe present invention downwind morphing wind turbine.

FIG. 1(D) provides a schematic view of the associated net forces summedat quarter elements on a respective blade of FIG. 1(C).

FIG. 1(E) provides an illustration of palm tree in high winds.

FIG. 1(F) provides a schematic view of the associated net forces summedat quarter elements on two respective blades of FIG. 1(C) along with thedeflection of curvature angles β and hub angle β.

FIG. 2(A) provides a schematic view of the associated net forces on arespective conventional blade of FIG. 1(A).

FIG. 2(B) provides a schematic view of the associated net forces on arespective blade of an embodiment of the present invention whichdemonstrates a free-coning blade so side-forces align with the blade.

FIGS. 3(A), 3(B), and 3(C) schematically illustrate the various forcesacting on turbine blade(s) in general from the front view, side view andchord view, respectively.

FIG. 4 provides a graphical representation of the average load-pathangles (β) (i.e., deflection curvature angle with the axis of rotationplane of the blade) in degrees at rated conditions as a function ofrated turbine power (P_(rated)) in MW.

FIG. 5 schematically illustrates an exemplary downwind morphing scheduleas a function of wind speed for the following: no morphing (FIG. 5(A));partial downwind morphing, such as starting with most outboard segment(FIG. 5(B); full downwind morphing (FIG. 5(C); stowed configuration(FIG. 5(D).

FIG. 6 schematically illustrates the blade segments joined or coupled asdesired or required.

FIG. 7 schematically shows an exploded view of the alignment of adjacentblade segments for a twist morphing embodiment.

FIG. 8(A) schematically shows a perspective view of the alignment ofadjacent blade segments for a twist morphing embodiment.

FIG. 8(B) schematically shows a perspective partial view of thealignment of adjacent blade segments shown in FIG. 8(A).

FIG. 9(A) schematically shows a perspective view of the alignment ofadjacent blade segments in a fully-wound (together) condition for atwist morphing embodiment.

FIG. 9(B) schematically shows a perspective view of the alignment ofadjacent blade segments in an unwound (separated) condition for a twistmorphing embodiment.

FIG. 10 provides a finite element analysis (FEA) of downwind morphingrotor blades at rated conditions for a 10 MW turbine showing surfacemeshes for conventional (see FIG. 10(A)) and morphed blades (See FIG.10(B). FIG. 10 further shows von Mises stress for: a conventional blade(See FIG. 10(C)) as well as a morphed blade with the same mass (See FIG.10(D)), and a morphed blade with 50% less mass (See FIG. 10(E))according to the stress color map in MPa provided in FIG. 10(F).

FIG. 11 schematically shows downwind morphing a) method to ensure zeromoment nodes (FIG. 11(A), and b) resulting downstream blade curvature(FIG. 11(B)).

FIG. 12 provides a graphical representation of the downwind morphingdeflection angle at each node and the resulting fit vs. the radialposition for fixed-mass and fixed-length.

FIG. 13 Aerodynamic shroud around the tower for reduced tower wakeeffects on the blades, wherein for illustration purposes the nacelle istranslucent (outlined with dashed lines) in context of the tower, huband blades.

FIG. 14 schematically shows a perspective view of Tripod floatingembodiment of the present invention (pre-alignment aspects or morphingnot shown).

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The wind turbine 100 illustrated in FIG. 1(A) is a modern conventionalturbine 100 that comprises a tower 104 supporting a nacelle 106. Asubstantially horizontal main shaft projects from the nacelle 106, arotor 102 being mounted on the shaft, the rotor comprising a hub 108 andtwo or more blades 110. The rotor 102 can be made to rotate by the wind.In this example, the wind turbine is a so-called upwind turbine, wherethe wind impinges on the rotor 102 before it impinges on the tower 104,and where the nacelle 106 is able to yaw, i.e. rotate around a verticalaxis with respect to the tower 104, the rotor thereby adjusting itselfto the wind direction at any given moment. Moreover, the wind turbine ispreferably provided with three blades 110 extending substantiallyradially outwards from the hub 108. Each blade 110 comprises a rootsection 116 near the hub 108 and a blade tip 114. Still referring toFIG. 1(A), upwind turbine configurations typically employ blades withfiberglass shells (or more expensive carbon fiber) to carry the gravity,acceleration and aerodynamic loads. Designing the blades to be stiffenough to resist the forces at rated conditions (FIG. 1B) leads to theblade mass problems. As shown in FIG. 1(B), the associated net forcessummed at quarter elements and are schematically shown by force arrows109 on a respective blade shown in FIG. 1(A). The angle of the blade 110is essentially aligned with the axis of rotation plane 132 of the blade.Load-adaptable blade geometry is not a new concept and in fact has beenused on many successful (and unsuccessful) systems by introducingflexibility. An example load-adaptable geometry is the Soft Rotorconcept [See Rasmussen, F., Petersen, J. T., Volund, P. Leconte, P,Szechenyi, E and Westergaard, C. “Soft rotor design for flexibleturbines.” in Riso National Laboratory. Roskilde, Denmark: ContractJOU3-CT95-0062, of which is hereby incorporated by reference herein inits entirety.], which employed flexible downwind blades that eliminatedthe need for mechanical yaw control. A two-bladed 15 kW (13 meterdiameter) design was fabricated and field tested and it was found thatthe rotor loads were reduced by 25-50% during operation (compared torigid upwind blades) while aerodynamic efficiency was approximatelyretained. Moreover, such a soft design can mitigate problematichigh-frequency fatigue loads, a concept already demonstrated for towerdesign [See Sear, D., “Wind turbine technology: Fundamental concepts inwind turbine engineering,” ASME 2009 (New York, N.Y.), of which ishereby incorporated by reference herein in its entirety.]. Otherexamples of adaptability to forces include coning designs, wheretypically two downstream blades are hinged at the hub. However, suchsystems are not widespread due to dynamics concerns with two-bladeddesigns, and structural designs for highly flexible blades.

The stiffness constraint can be relaxed if a downwind morphing conceptis employed as per the aspects of the various embodiments of the presentinvention. An aspect of an embodiment of the present concept does notnecessitate the use of a flexible rotor nor conventional coning, butinstead as shown in FIG. 1(C), employs a rotor 202 having threesegmented blades with stiff elements whose joints can be unlocked athigh-speeds to allow substantial downstream movement, i.e., downwindmorphing. It should be appreciated that the present invention flexiblerotor may employ two or more blade segments.

FIG. 1(C) provides a perspective view of an aspect of an embodiment ofthe present invention downwind morphing wind turbine 200 including amongother things, a nacelle 206, a rotor 202 being mounted on the shaft, therotor comprising a hub 208 and two or more segmented blades 210. Alsoshown is the deflection curvature angle β with the axis of rotationplane 232 of the blade. The rotor 202 is a downwind turbine from thetower 204 and nacelle 206 regarding the prevailing wind 203. Moreover,the wind turbine is preferably provided with three blades 210 extendingsubstantially radially outwards from the hub 208. Each blade 210comprises a root section 216 near the hub 208 and a blade tip 214.Although not specifically called out due to the limitations of theillustration, each blade is comprised of two or more blade segments (ofwhich will be discussed in detail in this disclosure). Between each thesegments (not specifically called out in FIG. 1(C)), the segments may becoupled with a hinge-like mechanism such as a ball joint, flex joint,pin joint, tension cabling, trunnion joint, or the like between them soas to be able to rotate or close downwind to provided downwind morphing.

As can be seen in FIG. 1(C), the tower 204 and the nacelle 206 may beprovided with an aerodynamic design, such as an aerodynamic shroud forinstance. Similarly, an enlarged view as shown in FIG. 13 will bediscussed below.

As schematically shown in FIG. 1(D), the associated net forces summed atquarter elements, which align along the blade 210 are schematicallyshown by force arrows 209 on a respective blade shown in FIG. 1(C). Theblade 210 has three blade segments 240 that may be joined at bladesegment joints 241. Also shown is the deflection curvature of angle βwith the axis of rotation plane 232 of the blade.

This concept has the advantage, but not limited thereto, in that it canstill employ low-cost low-deflection fiberglass materials andfurthermore, allows direct control of the degree of geometry change. Atrated conditions, the joints are designed to eliminate any downstreammoment so that gravity, centrifugal and aerodynamic loads only yieldmass-efficient tensile loads (and avoid mass-consuming cantileverloads). The result is a dramatic reduction in structural stresses sothat the blade mass may be dramatically reduced. As shown in FIG. 1(E),this concept can be, for example, compared to the flow adaptability ofthe palm tree, whose light-weight segmented trunk can be considered as aseries of cylindrical shells which can bend in the wind. FIG. 1(E)provides an illustration of palm tree in high winds. In contrast, theoak tree trunk is more like a solid (and much heavier) single-elementbeam which resists bending in moderate winds (like a conventionalrotor). However, monsoon storms and hurricanes will blow and uproot most“stiff” trees away. In contrast, the segmented morphing palm tree canbend all the way to the ground and survives hurricane strength winds.This adaptability to aerodynamic load via an extremely lightweightstructural design and thus, provides some of the principles of anembodiment of the present invention—Segmented Ultralight Morphing Rotor(SUMR).

Referring to FIG. 1(F), the associated net forces summed at quarterelements, which align along the blade 210 are schematically shown byforce arrows 209 on a respective blade shown in FIG. 1(C). The blade 210has three blade segments 240 that may be joined at blade segment joints241. Also shown is the deflection of curvature angle with the axis ofrotation plane 232 of the blade. For a particular example, but notlimited thereto, at rated conditions, the maximum deflection angles atthe top and bottom blade positions reach values of 18° (β_(up)) and 12°(β_(down)), respectively. These angles are a primarily a function ofblade weight, rotor rpm, and rotor power. In particular, the angles tendto increase as rotor power increases, especially for turbines which aregreater than 1 MW of rated power. To avoid cyclic variations of bladeangle of the blade 210 with respect to the rotating hub, i.e., axisrotation of the blade 232, teetering can be employed whereby theeffective rotation hub axis (θ) is inclined downward at a net angle,e.g. θ=½ (β_(up)−β_(down))=3°. This adaptability is quite beneficialsince it removes gravity cycling stresses, and the associated reductionin dynamic loads and fatigue in the entire system also reduces cost andimproves reliability. Teetering is most commonly used for two two-bladedsystems, and various embodiments of the present invention morphing canbe applied to one or more bladed turbines. In such cases, the rotor axiscan also be changed by titling the rotor shaft with respect to thegravitational plane. This may be driven and controlled with motors ormay be achieved using the downwind load forces to tilt the entire tower,e.g. for the case of a floating platform. It should be appreciated thatthe deflection of curvature angle β (β_(up) and β_(down)) and hub, angleθ may be designed to curve and align at any desired or required angle toachieve the intended or desired objective of turbine or rotor operation.

Furthermore, the downwind orientation may eliminate the need formechanical yaw. Another key point of the morphing concept is aerodynamicfairing of the nacelle and tower (as shown in FIG. 1(C)), minimizingtower wake effects [See Loth, E., Selig, M. S., and Moriarty, P.“Morphing segmented wind turbine concept,” in AIAA Applied AerodynamicsConference. 2010. Chicago, Ill. AIAA-2010-4400 paper, of which is herebyincorporated by reference herein in its entirety.]. In addition, thesegment pin joints are designed to prevent deflection in the torque-wisedirection since such moments (albeit small compared to the downstreamcantilever moment for a conventional rotor blade) are needed for powerextraction. Circumferential stiffness also allows conventional pitchcontrol, e.g. so blades can be faired above rated wind speeds. Theaddition of joints results in a small but finite weight penalty, butallows morphing to be locally focused at the blade tips whereaerodynamic and centrifugal forces are much higher than near the hub. Incontrast, a coning rotor that cannot adapt along the blade will havereduced aerodynamic performance.

An aspect of the present invention pre-aligned rotor blade or downwindmorphing rotor blade is that it provides, among other things, anaero-elastic design that reduces the downwind cantilever aerodynamicload to help reduce structural mass. Turning to FIG. 2, the distributionof forces at rated conditions for a conventional upwind rotor blade(FIG. 2(A)) and an embodiment of the present invention aligned downwindblade (FIG. 2(B)) and that demonstrates a free-coning blade soside-forces align with the blade, which eliminates downwind cantileverhub moments. This concept can be used for an embodiment of the presentinvention wind turbine to minimize rotor mass by avoiding theconventional stiffness constraint and instead adapting a downwindgeometry to align with the load path, i.e., net force 109, 209 as shownin FIGS. 2(A)-2(B). As shown in FIG. 2(A), it can be seen that theconventional blade 110 that is subjected to the prevailing wind 103 hasloading that leads to cantilever forces (i.e., net forces 109) in thedownstream direction. In contrast, referring to FIG. 2(B), an aspect ofan embodiment of the present invention rotor having the aligned conceptemploys a geometry that orients the loads (i.e., net force 209) alongthe blade length of the blade 210 so that the structural loads primarilyact in the tension mode. The blade 210, as shown, has four bladesegments 240 that may be joined at blade segment joints 241 to be ableto fold or close (partially or fully) downwind or may be fixed in“pre-aligned” or “aligned” fashion. The resulting load-path angles (β)(i.e., deflection of curvature angle with the axis of rotation of theblade) will vary as a function of radius and azimuthal angle, but thesechanges are minor. By converting loads to a tensile direction, thisconcept effectively uses design principles of cabled-stayed bridges andthe kite rotors to reduce mass by minimizing cantilever-based shearloads. However, the present downwind rotor design (for example, as shownin FIG. 2(B)) is unique in that it can avoid direct use of cables todirect loads in the tensile direction, and instead incorporatesaeroelastic adaptability bio-inspired by the palm tree. If thisalignment is fixed (independent of wind speed) and based on eliminatingcantilever loads at the rated condition (where peak loads occur), it istermed herein as a “pre-aligned” or “aligned” rotor. Note that anembodiment of the pre-aligned rotor (or “aligned” rotor) presentinvention provides, among other things, a design that is fixed inadvanced. In contrast, an embodiment of the morphing rotor of thepresent invention is as a function of wind speed. It should beappreciated that a morphing rotor can achieve the positions achieved bypre-aligned (aligned) rotor by implementing the appropriate coupling,materials, and structure as desired or required as is contemplatedwithin the context of the present invention. And vice versa, whereby itshould be appreciated that a pre-aligned rotor can achieve the positionsachieved by a morphing rotor by implementing the appropriate designcriteria as discussed herein.

To determine the typical angles needed to align a rotor blade with therated load conditions, an aspect of an embodiment of the presentinvention considers a decomposition of the forces which act on a turbineblade in general as shown in FIG. 3. These forces include the gravityforce (G), the centrifugal force (C), the downstream aerodynamic thrustforce (T), and the in-plane aerodynamic torque-wise force (F_(Q)). Notethat the latter two forces result from the aerodynamic drag force (D)and the lift force (L). FIGS. 3(A), 3(B), and 3(C) schematicallyillustrate the various forces acting on the turbine blades in generalfrom the front view, side view and chord view, respectively.

An aspect of an embodiment of the present invention entails theestimation of the net load-path angle (β) (i.e., deflection curvatureangle with the axis of rotation plane of the blade) in terms of thesenet forces and the azimuthal blade angle (φ, defined as 0 for a bladethat is pointed vertically upwards and π for a blade that is downwards)as:

$\begin{matrix}{\beta = {\tan^{- 1}\left( \frac{T}{C - {G\;\cos\;\varphi}} \right)}} & (1)\end{matrix}$This load-path angle is shown in FIG. 4 for the blade pointed upwards(β_(up), where φ=0) and downwards (β_(down), where φ=π=π) as a functionof turbine rated power. For moderate-size turbines (less than 1 MW), theload-path angle at rated conditions is small (typically less than 5deg.) so that some of this can be accommodated by aeroelastic deflectionfor an upwind conventional rotor. This indicates that aligned blades donot benefit small systems. However, for large- and extreme-scaleturbines the load-path angles can be large, e.g. more than 20 degreesfor a 20 MW system. This trend of increasing β with increasing P is aresult of size-scaling for a constant tip-speed (ω˜R⁻¹) such thatC˜R^(1.2) (Eqs. 2 and 5), T˜R² (Eqs. 1, 6 and 13), while G˜R^(2.2) (Eqs.2 and 4).

Since cantilever loads are more significant at extreme-scales, alignmentallows a larger reduction in the moments experienced by the blade (perFIG. 2). Furthermore, aligning the blade geometry at these large anglesdownstream necessitates a downwind rotor. Thus, scaling will driveextreme-scale systems to downwind aligned rotors. One may also note thatthere is a significant difference in the upwards and downwards load-pathangles in FIG. 4, which is due to the increased importance of gravityloads at extreme-scales. Additional differences in these load pathangles can occur if there is a vertical wind-shear across the rotorcausing higher wind speeds at higher altitudes. To avoid cyclicappearance of cantilever loads while maintaining a fixed rotor geometrywith respect to the hub, the hub axis can be tilted relative to thehorizon as a function of wind speed by θ as shown in FIG. 1(F). If atwo-bladed design is used, this tilting can instead be achieved bytilting the hub-axis or by teetering the rotor. For two- or three-bladeddesigns, individual pitch control and/or trailing edge surfaces (flapsor tabs) may accommodate tilt-pitch coupling as well as rapid changes inwind angle or speed caused by gusts. It should be noted that rotorspeeds above rated conditions will result in only a small reduction inthe load path angles, such that pre-alignment at rated conditions willbe nearly ideal. For rotor speeds below rated conditions, the load pathangles will generally not be aligned with those at rated conditions, butat these lower speeds the loads on the blades are substantially reducedso that the adaption is not needed to avoid peak stresses on the blades.

A qualitative downwind morphing schedule is shown in FIGS. 5(A)-(D) foran aspect of an embodiment of the present invention morphing windturbine 200 including among other things, a nacelle 206, a rotor 202,hub 208, blades 210, and tower 204 while exposed to a given prevailingwind 203. Referring to FIG. 5(A), for parked conditions and low-windspeeds, the turbine blades 210 are un-morphed since the stresses aregenerally small and dominated by gravity loads. For example, there is nomorphing at the range for about 0-8 m/s. Although not specificallycalled out, all of the blade segments 240 are generally shownsubstantially in the same plane. At low wind speeds below the cut-inwind speed, the rotor will be in a parked state where the rotor isperfectly vertical). As the wind speed increases above the cut-in speed,the rotor will start to turn and produce power. Referring to FIG. 5(B),as the wind speed increases further, centrifugal and aerodynamic loadscan dominate gravity loads such that the load path does vary stronglywith azimuthal angle. Once a segment has reached a loading level thatleads to a moderate downstream deflection angle (e.g. 18° or less), thejoints (starting first with the outermost joint) are sequentially areunlocked so the segment is free to deflect downstream. The initialdownwind morphing will have the outermost blade segment 252 angledcompared to both the middle blade segment 253 and inner blade segment254, which remain substantially in the same plane. As the wind speedincreases more and more of the segments will be free to align. Referringto FIG. 2(C), at rated conditions, all jointed segments of the blade arealigned so the rotor is fully morphed to minimize the stresses inducedby the high aerodynamic and centrifugal loads. The most outer bladesegment 252, middle blade segment 253, and inner blade segment 254 areall angled relative to one another. As the wind speeds increases aboverated conditions but are below the cut-out conditions, the rotor willremain fully morphed. For example, full morphing occurs at the range for14-28 m/s. Referring to FIG. 5(D), the segmentation can also be used to“stow” the rotor blades in very high wind-speeds, which occur whenhurricane-strength storms are possible. For example, stowedconfiguration for wind speeds above 28 m/s (nearing Category 1 Hurricanespeeds). The most outer blade segment 252 and middle blade segment 253are angled and in a common plane compared to the inner blade segment254. It should be appreciated that the angles of the blade segments andthe curvature of the blade segments themselves be designed to align andcurve at any desired or required angle or curvature to achieve theintended or desired objective of turbine or rotor operation.

It should be appreciated that any of the structures, devices orcomponents discussed herein may be controlled by a controller and/orappropriate motors or power source.

FIG. 6 provides an enlarged partial perspective view of a blade 201having multiple blade segments 252, 253, 254. In an embodiment, theblade segments are coupled, in communication, or joined at their respectjoints 241. The coupling may be accomplished by a joint such as atrunnion, hinge, pin joint, ball joint, flex joint, or cable. Inaddition, the hinge effect may be accomplished by material selection orstructural design. Additionally, the coupling may be accomplished by apivot mechanism, device or system. Moreover, the coupling may beaccomplished by an elastomeric material or other suitable coupling,adhesive, connecting, or joining approaches that are available. Theblade segmentation aspect can be especially transformative with respectto, but not limited thereto, manufacturing, transporting, and repairingsuch systems. This modularity, coupled with the reduced overall systemweight can break down barriers inherent to increasing the scale ofcurrent turbine designs. The outer blade segment 252 may or may notinclude the blade tip 216. Similarly, the inner blade segment 254 may ormay not include the root section (not shown).

It should be appreciated that any of the segments may be released at avariety of speeds, increments, or sequence. The release may beattributed to, for example, a variety of forces, cables, couplings andcontrollers.

The various embodiments of the present invention may be applicable to avariety of turbine sizes such as being larger than, equal to, or smallerthan the following ranges: a) 0.10 MW, 18 m D, 9 m blade; b) 0.75 MW, 50m D, 25 m blade; c) 1.5 MW, 66 m D, 33 m blade; d) 2.5 MW, 85 m D, 42.5m blade; e) 3.5 MW, 100 m D, 50 m blade; f) 5 MW, 120 m D, 60 m blade;and g) 20 MW, 240 m D, 120 m blade. It may be noted that while the twistmorphing could be used at all speeds it may not provide the mass savingsas would be the case associated with the downwind morphing orpre-aligned embodiments. It may be noted that the downwind morphingembodiment or pre-aligned embodiment will most likely be used forturbine size of approximately 1 MW or greater due to the associated masssavings.

Next, regarding downward morphing, a joint member 241 may be providedwith the appropriate joint or pivot (such as trunnion, hinge, pin joint,ball joint, flex joint, or cable) as desired or required the bladesegments can altered to provide for downwind morphing. It should beappreciated that the spar member of a blade may have a rectangular orother polygon cross-section shape rather than circular, oval or roundedshape. The blades and spars and their related components may utilize thedevices and methods of manufacturing disclosed in the references Athrough FF listed herein. The rotors, hubs, controllers, motors andother related components of the wind turbine may be implementedutilizing the devices and methods of manufacturing disclosed inreferences A through FF listed herein. The hinges between blade segmentsmay be implemented utilizing the devices and methods of manufacturingdisclosed in the references A through FF listed herein, such as thoseused for the approaches for coning, folding or collapsing blades. Thecomponents, structures and devices of the wind turbine disclosed hereinmay be implemented utilizing the materials specified in references Athrough FF listed herein.

For twist morphing, referring to FIG. 7, to achieve this bladesegmentation and adaptability of the various embodiments of the presentinvention a fundamentally new structural design is required. Inparticular, an aspect of an embodiment of the present invention providesspar members 244 within the blade segments 240 (near the quarter-chordline or other chord line location as desired or required to intend bladeand rotor design) that can be socketed together with a desired couplingmember 245, such as but not limited thereto, threaded joints 244, 246.Also shown is a skin 248 that at least covers the blade segments of theblade 210. A coupling member or device 245 (such as threaded spar joints244, 246) may be designed to have nearly zero friction (e.g. housed in ahydraulic joint) and the blade segments 240 are held together by atension member 250 (such as a cable or the like) as shown in FIG. 7. Thespar members 244 may have a circular cross-section or other geometricconfigurations that is suitable or desirable for operation. Couplingmembers 245 are providing for joining or interfacing the spar members244 together or in communication with each other, and may be anycoupling device, mechanism, or approach. As illustrated in FIG. 7, thecoupling member 245 is an internal threaded joint 246 and externalthreaded joint 247. The threaded joints of the spar members 244 may beany coupling device, mechanism, or approach. The tension cable 250 canrun, for example, from the blade tip 214 to the rotor hub 208 (tip andhub shown in FIG. 1(C) for example) where it can be attached by a springand dash-pot damper system (dash-pots may also be placed at the joints).A hub cam can be used to provide eccentricity so that the cable tensionremains constant despite changing gravitational loads as the blades movefrom the up to down positions. The dashpot is a mechanical device, adamper which resists motion via viscous friction. The resulting force isproportional to the velocity, but acts in the opposite direction,slowing the motion and absorbing energy. Dashpot can be used inconjunction with a spring (which acts to resist displacement). It shouldbe appreciated that other available motion resistant or dampeningsystems and mechanisms may be utilized as desired or required.

For twist morphing, FIG. 8(A) provides a perspective view of the twoblade segments 240 and associated components and FIG. 8(B) provides anenlarged partial perspective view of a blade segment of FIG. 8(A). FIG.8(A) provides two blade segments 240 that may be utilized as part of arotor blade for a rotor of wind turbine. The blade segments may includean internal passage 242 extending longitudinally from a first end to asecond end of each of said blade segments. Spar members 244 extendlongitudinally (i.e., span wise) through said internal passages of eachof said blade segments such that the plurality of the spar members maybe aligned and in communication end-to-end (i.e., span wise) throughsaid internal passages. Additionally, the blade segments 240 are alignedand in communication with spar members 244 to form a rotor blade. Thespar members 244 may be joined by a coupling or connecting mechanism,system or device 245 such as a threaded joint. The external portion 246of the threaded joint of the spar member 244 is shown in FIG. 8(A) andthe internal portion 247 of the threaded joint of the spar member 244 isshown in FIG. 8(B). A tension member 250 is provided that extendslongitudinally through said aligned spar members 244. The aligned sparmembers are configured to be free to twist and at least partially unwinddue to centrifugal forces exerted on the blade segments and the alignedspar members. As a result, the free or unwound spar members will causethe blade segments to twist and provide a twist type morphing. It shouldbe appreciated that the twisted blade segments can be designed to alignand curve at any desired or required angle or curvature to achieve theintended or desired objective of turbine or rotor operation. The tensionmember comprises at least one of the following: cable, rod, chain, rope,etc. or other available elongated member. It should be appreciated thatthe spar members may run along inside the blade segments at any desiredor required location. Similarly, the span members may run as part of thewall of the blade segment itself, or even outside the wall of the bladesegment.

Moreover, for twist morphing, one or more curvature coupling mechanisms245 of the spar and/or blade segments joints 241 may be provided withthe appropriate joint or pivot (such as trunnion, hinge, pin joint, balljoint, flex joint, or cable) as desired or required the blade segmentscan altered to provide for twist morphing.

For twist morphing, it should be appreciated that the spar member mayhave a rectangular or other polygon shape rather than circular, oval orrounded shape.

For twist morphing, FIG. 9 provides a perspective view of a portion of ablade 210 illustrating blade segments 240, spar members 244, spar jointsor sockets (revealing the external threaded joints 246 in theillustration), and tension member 250. At wind speeds below the ratedwind speed, this cable tension may be set so that the spar members 246are “fully threaded” and the blade segments are together (See FIG.9(A)). The fully-threaded position will be associated with the maximumgeometric twist of the blade from the plane of rotation, to give areasonable angle of attack for low winds. At wind speed increases beyondthe rated speed, the rotor tip speed will also increase but a constantpower is desired to match the generator capability. The tension can beset so that the increased rpm will result in centrifugal forces whichwill cause the spar members 244 and blade segments 240 to pull apart andthus the spar members 244 will unwind to reduce the effective angle ofattack and maintain constant power (see FIG. 9(B)). FIG. 6(B)illustrates the unwound condition for high speeds, for example. Theblade segmentation will lead to small structural gaps 249, but these canbe covered with an elastomeric sheath (not shown in FIG. 9) toaerodynamically cover the gap 249 extension resulting from any amount ofunwinding. This feathering will tend the blade toward an optimum pitchto prevent stall and the associated unsteady torques. This control issimilar to that used in a Jacob turbine whereby centrifugal forceschange pitch (by overcoming spring tension) to avoid over-speed. Notethat the Jacob's concept ensured that all three blades changed pitchsimultaneously. While an aspect of an embodiment of the presentinvention does not require this same consistency mechanically, and theaddition of fine-scale pitch control (e.g. with fast-acting tabs nearthe trailing edge of the airfoil) may be sufficient to keep aerodynamicbalance for extreme-scale systems. The threading angle at each joint canbe uniquely designed to achieve optimum twist changes over the mostoutboard (power cable producing) blade span at each wind-speed (which isassociated with a unique quasi-steady turbine rpm).

Segmenting allows much higher effective twist control thansingle-element concepts since small angles between segments can lead tolarge overall twist. This is desirable since the optimal pitch angle canvary by as much as 20 deg. above the rated wind speed [See Wilson “WindTurbine Aerodynamics, Part A Basic Principles” in “Wind TurbineTechnology,” edited by Spera, D. A., ASME Press, New York, N.Y., 2009,the disclosure of which is hereby incorporated by reference herein].This quasi-steady speed-tailored feathering can reduce the need fordynamic pitch control (which may help reduce overall system mass andthus cost) though full-span pitch control and system braking can beprovided to prevent over-speed above the set maximum blade rotationrate.

EXAMPLES

Practice of an aspect of an embodiment (or embodiments) of the inventionwill be still more fully understood from the following examples andexperimental results, which are presented herein for illustration onlyand should not be construed as limiting the invention in any way.

Example Set No. 1

To demonstrate reduction of structural stresses and blade mass, finiteelement analysis (FEA) has been conducted by the Applicants at ratedpower conditions for conventional vs. segmented morphing rotors. Thesimulated rotors employed a fiberglass shell with the aerodynamic moldlines (including airfoil shape, size, and twist as a function of rotorradius) of the NREL 5 MW reference turbine blade, but scaled (SeeJonkman, J., Butterfield, S., Musial, W., Scott, G., “Definition of a5-MW reference wind turbine for offshore system development,” NRELTechnical Publishing, 2009 (NREL/TP-500-38060, of which is herebyincorporated by reference herein in its entirety.) to a 10 MW system.The surface discretizations are shown in FIGS. 7(A) and 7(b). Thedownwind morphed geometry was determined based on a zero net moment inthe downstream direction but retained the finite torque-wise(power-producing) moment about the hub axis.

The von Mises stresses for the conventional and downwind morphed bladeat rated conditions are shown in FIG. 10(C) and FIGS. 10(D)-7(E) forvertical upwards position (where morphing is largest). When blade massis fixed, the stresses are reduced by more than 85% (with similarreductions for horizontal and vertical downward positions). This isbecause the combination of gravity, centrifugal and aerodynamic loadsare all directed in an efficient tensile path (FIG. 10(D)) and since theremaining out-of-plane torque-wise loads arc less than 4% in comparison.In contrast, the conventional rotor blade must carry these loads in acantilever mode (FIG. 10(C)) which induces substantial shear stresses.Even when the downwind morphing blade mass is reduced by 50%, thestresses are still below those for a conventional rotor. It isnoteworthy that the rotor mass savings increases with size. Since towermass depends to some degree on rotor mass, this shows that the SUMRconcept can substantially decrease system mass, while increasing powercapture.

Example Set No. 2

Transformational Cost Reduction

The various aspects of embodiments of the present invention SUMR designdirectly addresses, among other things, cost of energy (COE) reductiongoals for offshore or land wind turbines in a number of ways. Themorphing rotor design of various embodiments of the present inventionsignificantly reduces both of the rotor and overall turbine fatigue andextreme loads, allowing a significant mass and cost reduction both inthe rotor itself and in the balance of the turbine's overall load path.The reduction in loads and tower head mass allows the reduction of massand cost for the turbine tower and foundation system as well.

Referring to Tables, 1, 2 and 3, to illustrate the potential COEreductions possible with a next generation offshore wind turbine basedon the SUMR turbine, the proposed configuration has been compared to abaseline turbine design using the NREL Wind Turbine Design Cost andScaling Model, see Table 1. The NREL model defines a PMDD 10 MW offshoreturbine reference configuration, which was selected as the baselineconfiguration. For offshore applications the model assumes an annualaverage wind resource of 9.16 m/s at 50 m above water level, yielding 10m/s at the selected hub height. The complete model is available fordetailed review, with key output results included in this section. Anadvanced configuration was then defined based on SUMR, in conjunctionwith a permanent magnet, direct drive (PMDD) drivetrain topology basedon Northern Power's current 2.3 MW onshore turbines. The SUMR designenables a significant increase in the rotor diameter and swept area,while still allowing a significant reduction in mass and cost for theoverall wind turbine.

TABLE 1 Description Operating Parameters for the Turbine & WindOperating Parameter Inputs Offshore 10.0 MW Proposed Baseline (PMDD)Turbine Land Based or Offshore? Offshore Offshore Machine Rating (kWs)10000 10000 Rotor Diameter (meters) 175 206 Hub Height (meters) 120 120Wind Speed @ Hub Height 10 10 Weibul KFactor 2 2 Wind Shear 0.1 0.1 MaxRotor Op 0.482 0.482 Max Tip Speed m/s 80 80 Max Tip Speed Ratio 8 8Wind Farm Size in MWs 250 250 Total Non-Drivetrain Losses 10% 10%Availability 95% 96% Drive Train Design PMDD PMDDAs compared to the baseline configuration, the SUMR turbine offers, seeTable 2:

-   -   Increased rotor swept area by 38% (since larger rotor is        possible due to reduced mass), leading to increased energy        capture of 13%.    -   Reduced rotor and load path mass and cost, leading to lower        turbine capital cost.    -   Reduced tower and foundation mass and cost, leading to lower        turbine and balance of system cost.    -   Reduced transportation costs due to segmentation.

TABLE 2 Annual Energy Wind Farm Production Survey RepresentativeOffshore 10.0 MW Proposed Categories Baseline (PMDD) Turbine ImprovementTotal Installed   250,000   250,000 Capacity (kW) AEPtot (MWh/yr)1,188,499 1,329,053 12% EL (total losses %) 10% 10% Availability (%) 95%96%  1% AEPnet (MWh/yr) 1,016,167 1,148,302 13% Capacity Factor 46.40%  52.43%   13%

TABLE 3 Wind Energy Systems COE Summary Representative Offshore 10.0 MWProposed Categories Baseline (PMDD) Turbine Improvement Turbine Capital$0.037 $0.030 21% Cost ($/kWh) Balance of System $0.075 $0.052 30% Cost($/kWh) Operations & Maint. $0.018 $0.014 24% Cost ($/kWh) LevelizedReplcmt. $0.003 $0.002 21% Cost ($/kWh) Total System $0.133 $0.098 27%($/kWh)

The proposed turbine is focused on the SUMR configuration to isolate theimprovements directly attributable to this innovative concept. FurtherCOE reductions may result by combining other advanced rotor and balanceof turbine improvements with SUMR. For example, Northern Power isextending its highly modular PMDD drivetrain technology to largeoffshore wind turbines, which will further increase energy capture andreduce O&M and LRC costs with respect to the baseline turbineconfiguration. The combination of these achievable improvements willmeet and exceed DOE's goals of COE of below 10 cents per kWh by 2020,and potentially pave the path to DOE's goal of COE below 7 cent per kWhby 2030.

These cost saving are realized because morphing reduces rotor mass andsegmentation and modularity simplifies fabrication, transportation,assembly, and maintenance. This allows a COE reduction of as much as 27%as compared to a conventional wind turbine. Such cost savings can breakdown the barriers inherent to extreme-scale off-shore wind turbines, buttheir realization requires detailed design, experimental fielddemonstration as well as detailed cost and commercial viabilityanalysis, as is proposed herein.

Example Set No. 3

Finite Element Analysis for Fixed-Mass Aligned Blade

To determine the stresses expected on a fixed-mass aligned downstreamblade, a 10 MW aligned blade was created. The mass, thickness, andgeometry were held constant and the same aerodynamic forces were appliedas used for the conventional 10 MW blade. The only difference was thatthe aligned blade included downstream curvature. In order to determinethe alignment angles, the blade 210 was segmented into four sections.For each segment 240, the total aerodynamic, centrifugal, andgravitational forces were calculated and assumed to act at the center ofeach section. Using the force values 209 (“F”), the angle β at eachjoint 241 was set so that the net downstream moment (“M”) at the nodepoints was zero, as shown in FIG. 11(A). Once the necessary angles foreach of the four joints were found, the geometry was created to matcheach joint angle. The resulting shape and computational mesh,representing the blade 210, are shown in FIG. 11(B), where it can beseen that the blade geometry can be approximately represented asdownwind coned. The detailed deflection angle is shown in FIG. 12, wherea range from 16-19 deg over the blade radius can be observed.

FEA was then used in order to determine the stresses in the alignedblade. A mesh of 14,997 shell elements was created in ANSYS again with amaximum element size of 0.5 m (FIG. 11(B). Applying the aerodynamic,centrifugal, and gravitational forces using the same method as for theconventional blade, the Von Mises stresses shown in FIG. 22 werecalculated. The peak Von Mises stress found was 19 MPa (an 82% stressreduction compared with conventional) and the average stress was 9 MPa(an 85% stress reduction compared with conventional). This demonstratesthe substantial benefit of alignment in reducing stresses, and thusstiffness requirements on the blade. It should be noted that the sweptarea has been reduced by 9% for this case since blade length was keptfixed.

Example Set No. 4

Segmentation and Shadow Effects

A concern about using a downwind rotor may be the wake effects of thetower on the blade. These can be problematic as they induce unsteadinessin blade loading that can lead to blade fatigue. However, they can bemitigated in two ways. Firstly, the tower can be aerodynamically fairedas shown in FIG. 13. This can have a substantial impact since the drag(and wake of an airfoil) can be many times less than that of a cylinder.

The shroud can be set to externally rotate around a fixed cylindricalstructure. The shroud rotation can be passive by allowing aerodynamicforces to align in the proper downstream direction. Since the wakeeffects are strongest near the outer portion of the blade (where most ofthe torque and downwind loading occurs), the aerodynamic shrouding mayonly be required for the section of the tower that are just upstream ofthe outer blade passage. Furthermore, the geometric downwind curvaturealso helps alleviate the tower shadow wake effects since the blade tips(where the effect can be most problematic) are shifted far downstream ofthe tower from pre-alignment. Active yaw control requirements may alsobe significantly reduced as a result of this downwind design¹². For verydeep waters (>60 m), a downwind rotor could also allow for a floatingtripod system 207 as shown in FIG. 14. The upstream floating pod couldbe cabled below to the sea floor so the thrust force aligns the turbineto the wind (self-yawing). Such a tripod platform (vs. a single columntower) may also help reduce wake effects since the increased stiffnessassociated with a broader platform allows smaller elements. This couldalso reduce tower mass since columnar designs at large scales can becomecostly and large.

The following patents, applications and publications as listed below andthroughout this document are hereby incorporated by reference in theirentirety herein. The devices, systems, compositions, computer programproducts, non-transitory computer readable storage medium, and methodsof various embodiments of the invention disclosed herein may utilizeaspects disclosed in the following references, applications,publications and patents and which are hereby incorporated by referenceherein in their entirety:

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In summary, while the present invention has been described with respectto specific embodiments, many modifications, variations, alterations,substitutions, and equivalents will be apparent to those skilled in theart. The present invention is not to be limited in scope by the specificembodiment described herein. Indeed, various modifications of thepresent invention, in addition to those described herein, will beapparent to those of skill in the art from the foregoing description andaccompanying drawings. Accordingly, the invention is to be considered aslimited only by the spirit and scope of the following claims, includingall modifications and equivalents.

Still other embodiments will become readily apparent to those skilled inthis art from reading the above-recited detailed description anddrawings of certain exemplary embodiments. It should be understood thatnumerous variations, modifications, and additional embodiments arepossible, and accordingly, all such variations, modifications, andembodiments are to be regarded as being within the spirit and scope ofthis application. For example, regardless of the content of any portion(e.g., title, field, background, summary, abstract, drawing figure,etc.) of this application, unless clearly specified to the contrary,there is no requirement for the inclusion in any claim herein or of anyapplication claiming priority hereto of any particular described orillustrated activity or element, any particular sequence of suchactivities, or any particular interrelationship of such elements.Moreover, any activity can be repeated, any activity can be performed bymultiple entities, and/or any element can be duplicated. Further, anyactivity or element can be excluded, the sequence of activities canvary, and/or the interrelationship of elements can vary. Unless clearlyspecified to the contrary, there is no requirement for any particulardescribed or illustrated activity or element, any particular sequence orsuch activities, any particular size, speed, material, dimension orfrequency, or any particularly interrelationship of such elements.Accordingly, the descriptions and drawings are to be regarded asillustrative in nature, and not as restrictive. Moreover, when anynumber or range is described herein, unless clearly stated otherwise,that number or range is approximate. When any range is described herein,unless clearly stated otherwise, that range includes all values thereinand all sub ranges therein. Any information in any material (e.g., aUnited States/foreign patent, United States/foreign patent application,book, article, etc.) that has been incorporated by reference herein, isonly incorporated by reference to the extent that no conflict existsbetween such information and the other statements and drawings set forthherein. In the event of such conflict, including a conflict that wouldrender invalid any claim herein or seeking priority hereto, then anysuch conflicting information in such incorporated by reference materialis specifically not incorporated by reference herein.

We claim:
 1. A rotor blade for a wind turbine, said blade comprising: aplurality of blade segments for use as part of a rotor; each of saidplurality of blade segments comprising an internal passage extendinglongitudinally from a first end to a second end of each of said bladesegments; a plurality of spar members extending longitudinally throughsaid internal passages of each of said blade segments such that saidplurality of said spar members are aligned and in communicationend-to-end through said internal passages and said plurality of bladesegments are aligned and in communication with said aligned spar membersand define a complete rotor blade from a root that connects to a rotorhub to a blade tip of said rotor blade; a tension member extendinglongitudinally through said aligned spar members, said tension memberconfigured to exert a force longitudinally toward said rotor hub toestablish a first pitch configuration of said plurality of bladesegments in the absence of centrifugally-induced rotation of said bladesegments about an axis of said longitudinally-extending plurality ofspar members; wherein said aligned spar members are configured to rotaterelative to one another about said axis in response to centrifugalforces exerted on said blade segments and said aligned spar members dueto a prevailing wind, and in response, said blade segments areconfigured to rotate relative to one another to establish a second pitchconfiguration.
 2. The rotor blade of claim 1, wherein said tensionmember comprises at least one of the following: cable, rod, chain, orrope.
 3. The rotor blade of claim 1, wherein said first pitchconfiguration includes a higher angle of attack for said plurality ofblade segments as compared to said second pitch configuration.
 4. Therotor blade of claim 3, wherein the second pitch configuration includesan angle of attack below a stall threshold for said plurality of bladesegments.
 5. The rotor blade of claim 1, wherein said communication ofsaid plurality of spar members includes a threaded coupling betweenadjacent spar members.
 6. The rotor blade of claim 1, wherein saidrotation of said plurality of spar members relative to one anotherinduces gaps between adjacent blade segments; and wherein the rotorblade of claim 1 further comprises at least one sheath configured tocover said induced gaps between adjacent blade segments.
 7. The rotorblade of claim 6, wherein the sheath is elastomeric.
 8. The rotor bladeof claim 1, wherein a cross section of each of said spar members iscircular.
 9. A method of manufacturing a rotor blade for a wind turbine,said method comprising: providing a plurality of blade segments for useas part of a rotor; each of said plurality of blade segments comprisingan internal passage extending longitudinally from a first end to asecond end of each of said blade segments; providing a plurality of sparmembers extending longitudinally through said internal passages of eachof said blade segments such that said plurality of said spar members arealigned and in communication end-to-end through said internal passagesand said plurality of blade segments are aligned and in communicationsaid aligned spar members and define a complete rotor blade from a rootthat connects to a rotor hub to a blade tip of said rotor blade;providing a tension member extending longitudinally through said alignedspar members, said tension member configured to exert a forcelongitudinally toward said rotor hub to establish a first pitchconfiguration of said plurality of blade segments in the absence ofcentrifugally-induced rotation of said blade segments about an axis ofsaid longitudinally-extending plurality of spar members; and whereinsaid aligned spar members are configured to rotate relative to oneanother about said axis in response to centrifugal forces exerted onsaid blade segments and said aligned spar members due to a prevailingwind, and in response, said blade segments are configured to rotaterelative to one another to establish a second pitch configuration. 10.The method of claim 9, wherein said first pitch configuration includes ahigher angle of attack for said plurality of blade segments as comparedto said second pitch configuration.
 11. The method of claim 10, whereinthe second pitch configuration includes an angle of attack below a stallthreshold for said plurality of blade segments.
 12. The method of claim9, wherein said communication of said plurality of spar members includesa threaded coupling between adjacent spar members.
 13. The method ofclaim 9, wherein said rotation of said plurality of spar membersrelative to one another induces gaps between adjacent blade segments;and wherein the rotor blade further comprises at least one sheathconfigured to cover said induced gaps between adjacent blade segments.14. The method of claim 9, wherein said tension member comprises atleast one of the following: cable, rod, chain, or rope.
 15. A rotorblade kit for forming rotor blade on a wind turbine, said kitcomprising: a plurality of blade segments for use as part of a rotor;each of said plurality of blade segments comprising an internal passageextending longitudinally from a first end to a second end of each ofsaid blade segments; a plurality of spar members for extendinglongitudinally through said internal passages of each of said bladesegments such that said plurality of said spar members are aligned andin communication end-to-end through said internal passages and saidplurality of blade segments are aligned and in communication saidaligned spar members and define a complete rotor blade from a root thatconnects to a rotor hub to a blade tip of said rotor blade; a tensionmember for extending longitudinally through said aligned spar members,said tension member configured to exert a force longitudinally towardsaid rotor hub to establish a first pitch configuration of saidplurality of blade segments in the absence of centrifugally-inducedrotation of said blade segments about an axis of saidlongitudinally-extending plurality of spar members; and wherein saidaligned spar members are configured to rotate relative to one anotherabout said axis in response to centrifugal forces exerted on said bladesegments and said aligned spar members due to a prevailing wind, and inresponse, said blade segments are configured to rotate relative to oneanother to establish a second pitch configuration.
 16. The rotor bladekit of claim 15, wherein said first pitch configuration includes ahigher angle of attack for said plurality of blade segments as comparedto said second pitch configuration.
 17. The rotor blade kit of claim 16,wherein the second pitch configuration includes an angle of attack belowa stall threshold for said plurality of blade segments.
 18. The rotorblade kit of claim 15, wherein said communication of said plurality ofspar members includes a threaded coupling between adjacent spar members.19. The rotor blade kit of claim 15, wherein said rotation of saidplurality of spar members relative to one another induces gaps betweenadjacent blade segments; and wherein the rotor blade kit furthercomprises at least one sheath configured to cover said induced gapsbetween adjacent blade segments.
 20. The rotor blade kit of claim 15,wherein said tension member comprises at least one of the following:cable, rod, chain, or rope.